Microwave packaging

ABSTRACT

A container for heating a plurality of food items with microwave energy. The container has a tray with a sidewall extending at least partially around an interior of the tray, an insert disposed at least partially in the interior of the tray, and a plurality of receptacles at least partially defined by the insert. Each receptacle of the plurality of receptacles can be for at least partially receiving at least one food item of the plurality of food items.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/241,974, filed Oct. 15, 2015.

INCORPORATION BY REFERENCE

The disclosure of U.S. Provisional Patent Application No. 62/241,974,filed Oct. 15, 2015, is hereby incorporated by reference as if presentedherein in its entirety and is incorporated by reference for allpurposes.

BACKGROUND OF THE DISCLOSURE

The present disclosure relates to blanks, containers, trays, constructs,and various features to facilitate forming a container.

SUMMARY OF THE DISCLOSURE

In general, one aspect of the disclosure is generally directed to acontainer for heating a plurality of food items with microwave energy.The container can comprise a tray comprising a sidewall extending atleast partially around an interior of the tray, an insert disposed atleast partially in the interior of the tray, and a plurality ofreceptacles at least partially defined by the insert. Each receptacle ofthe plurality of receptacles can be for at least partially receiving atleast one food item of the plurality of food items.

In another aspect, the present disclosure is generally directed to aninsert for being disposed in an interior of a tray to form a containerfor heating a plurality of food items with microwave energy. The insertcan comprise a plurality of lateral ribs and a plurality of longitudinalribs. Each lateral rib of the plurality of lateral ribs can engage eachlongitudinal rib of the plurality of longitudinal ribs. A plurality ofreceptacles can be at least partially defined by at least one of thelateral ribs of the plurality of lateral ribs and at least one of thelongitudinal ribs of the plurality of longitudinal ribs. Each receptacleof the plurality of receptacles can be for receiving at least one fooditem of the plurality of food items.

In another aspect, the present disclosure is generally directed to amethod of forming a package. The method can comprise obtaining a traycomprising a sidewall extending at least partially around an interior ofthe tray, and at least partially forming a container by positioning aninsert at least partially in the interior of the tray. The insert can atleast partially define a plurality of receptacles. The method furthercan comprise inserting a plurality of food items into the container bypositioning at least one food item of the plurality of food items atleast partially into each receptacle of the plurality of receptacles.

Those skilled in the art will appreciate the above stated advantages andother advantages and benefits of various additional embodiments readingthe following detailed description of the embodiments with reference tothe below-listed drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

According to common practice, the various features of the drawingsdiscussed below are not necessarily drawn to scale. Dimensions ofvarious features and elements in the drawings may be expanded or reducedto more clearly illustrate the embodiments of the disclosure.

FIG. 1A is a schematic perspective view of a container according to afirst embodiment of the disclosure.

FIG. 1B is a schematic top view of the container of FIG. 1A.

FIG. 2A is a schematic perspective view of an insert of the container ofFIG. 1.

FIG. 2B is a schematic top view of the insert of FIG. 2A.

FIGS. 3A and 3B are schematic side views of respective ribs of theinsert of FIGS. 2A and 2B.

FIG. 4 is a schematic perspective view showing the erection of theinsert of FIGS. 2A and 2B from the ribs of FIGS. 3A and 3B according tothe first embodiment of the disclosure.

FIG. 5A is a schematic perspective view of the insert of FIGS. 2A and 2Bin a collapsed configuration according to the first embodiment of thedisclosure.

FIG. 5B schematically shows a transition of the insert of FIGS. 2A and2B between the collapsed configuration of FIG. 5A and the erectedconfiguration of FIG. 2A according to the first embodiment of thedisclosure.

FIG. 6 is a schematic top view of a package formed from the container ofFIGS. 1A and 1B with food products according to the first embodiment ofthe disclosure.

FIG. 7 is a schematic top view of a package formed from the container ofFIGS. 1A and 1B with food products and a susceptor cover according to analternative embodiment of the disclosure.

FIG. 8A is a schematic perspective view of a container according to asecond embodiment of the disclosure.

FIG. 8B is a schematic top view of the container of FIG. 8A.

Corresponding parts are designated by corresponding reference numbersthroughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present disclosure relates generally to various aspects ofcontainers, constructs, trays, inserts, materials, packages, elements,and articles, and methods of making such containers, constructs, trays,inserts, materials, packages, elements, and articles. Although severaldifferent aspects, implementations, and embodiments are disclosed,numerous interrelationships between, combinations thereof, andmodifications of the various aspects, implementations, and embodimentsare contemplated hereby. In one illustrated embodiment, the presentdisclosure relates to a container or tray for holding, heating, and/orcooking food items or various other articles. However, in otherembodiments, the container or tray can be used to form other non-foodcontaining articles or may be used for refrigerating or other uses.

FIGS. 1A and 1B illustrate a container 5 with a generallyrectangular-shaped receptacle or tray 7 and a grid-like insert 9according to a first embodiment of the disclosure. In the illustratedembodiment, the insert 9 is removably disposed in an interior 11 of thetray 7. Alternatively, the insert 9 could be glued or otherwise securedto an interior surface 13 of the tray 7. The container could beotherwise shaped, arranged, positioned, and/or configured withoutdeparting from the disclosure.

As shown in FIGS. 1A-1C, the tray 7 generally includes a bottom wall 21,a sidewall 23 with curved corners, and a flange 25 extending outwardlyfrom a top end of the sidewall 23. The tray 7 can be curved at thetransition between the bottom wall 21 and the sidewall 23. The tray 7can be press formed and/or erected from a blank (not shown). It isunderstood that the blank can be press-formed into the tray 7 by aforming tool (not shown) and/or through a one-step or multi-step formingprocess by which the blank is cut from a supply stock and press-formedinto the tray 7 by any suitable forming tool assembly. Alternatively,the tray 7 could be erected from one or more blanks (not shown) such asby folding and/or gluing different aspects of the blank(s) to form thetray. Also, the tray 7 could be omitted and/or could be alternativelyformed without departing from the scope of this disclosure.

The tray 7 can be formed from a single layer, such as, but not limitedto, paperboard, cardboard, paper, or a polymeric sheet. Alternatively,the tray 5 can be formed from more than one layer (e.g., a laminate). Inaccordance with the exemplary embodiments of the present disclosure, alaminate can include a lamination layer mounted on a substrate or baselayer (e.g., a polymer lamination layer on a paperboard substrate). Inone embodiment, the lamination layer could be disposed on an interiorside of the substrate. Alternatively, the tray 7 could be formed of anysuitable material or suitable combination of materials. For example, thetray 7 could include a molded polymer. In the illustrated embodiment,the tray 7 includes a susceptor 27 disposed (e.g., coated and/oradhered) on the interior surface 13 of at least the bottom wall 21. Thetray 7 could be otherwise shaped, arranged, positioned, and/orconfigured without departing from the disclosure. For example, thesidewall 23 could have any suitable number of corners or the cornerscould be omitted and the sidewall 23 could be circular or elliptic inalternative embodiments.

As shown in FIGS. 2A and 2B, the insert 9 includes seven lateral ribs 31(FIG. 3A) engaged with three longitudinal ribs 33 (FIG. 3B) so that theribs form the respective sides of a plurality of receptacles 35. In theillustrated embodiment, the insert 9 defines interior receptacles andmarginal receptacles. Each of the interior receptacles has four sides 36a defined by portions of respective ribs 31, 33. In particular, eachinterior receptacle can have two opposing sides defined by respectiveportions of two adjacent lateral ribs 31 and two opposing sides definedby respective portions of two adjacent longitudinal ribs 33. As shown inFIGS. 1A-2B, the marginal receptacles can have three sides 36 b definedby portions of the ribs 31, 33 and one side 36 c defined by a portion ofthe sidewall 23 or two sides 36 b defined by portions of the ribs 31, 33and a curved side 36 c defined by a respective corner of the sidewall23. In particular, each marginal receptacle can include two opposingsides defined by the respective end portions of two adjacent lateralribs 31, a side defined by a portion of one of the longitudinal ribs 33,and a side defined by a portion of the sidewall 23; two opposing sidesdefined by the respective end portions of two adjacent longitudinal ribs33, a side defined by a portion of one of the lateral ribs 31, and aside defined by a portion of the sidewall 23; or two sides defined bythe respective end portions of one of the lateral ribs 31 and one of thelongitudinal ribs 33 and two sides defined by a respective corner of thesidewall 23. As shown in FIGS. 1A and 1B, the bottom wall 21 of the tray7 can form the bottom of the receptacles 35 when the container 5 isassembled.

As shown in FIGS. 2A and 2B, the insert 9 can include a center panel orcentral panel 37 that at least partially extends over and at leastpartially covers (e.g., blocks) four of the receptacles 35 in the centerof the insert 9. In the illustrated embodiment, the central panel 37engages top edges of three lateral ribs 31 and three longitudinal ribs33 in the central portion of the insert 9, and, in one embodiment, thecentral panel 37 can be adhered to and/or integral with one or more ofthe ribs 31, 33. One or more of the covered portions of the ribs 31, 33can be recessed to at least partially accommodate the central panel 37so that the upper surface of the central panel can be coplanar with theupper edges of the ribs. As shown in FIGS. 1A-3D, the center panel 37can include a recess 39 for holding a secondary food item (e.g., dippingsauce, spices, other flavorings, etc.) and/or a secondary container forholding a secondary food item. Such a secondary food item (not shown)can be a food item that does not need to be heated as much as theprimary food item and/or that is more easily heated by microwave energythan the primary food item since the central portion of the container 5will generally be exposed to less microwave energy than a remainder ofthe container due to the electromagnetic field distribution in thecontainer. The insert 9 could be otherwise shaped, arranged, positioned,and/or configured without departing from the disclosure. For example,the central panel 37 could be omitted, could be a different size and/orshape (e.g., to at least partially cover more or fewer of thereceptacles 35), and/or could be otherwise positioned in the insert 9(e.g., not aligned with the center of the insert). Additionally, therecess 39 could be omitted or could have a different size, position,and/or shape and/or the central panel 37 could include any suitablenumber of recesses. Further, the insert could extend over a differentnumber of lateral ribs 31 and/or longitudinal ribs 33.

As shown in FIG. 2B, the seven lateral ribs 31 can extend in a lateraldirection L2 and can be spaced apart from one another in a longitudinaldirection L1. Similarly, the three longitudinal ribs 33 can extend inthe longitudinal direction L1 and can be spaced apart from one anotheralong the lateral direction L2. Accordingly, the insert 9 can formthirty two receptacles 35 in the tray 7 when the container 5 is formed(FIGS. 1A, 1B, 6, and 7) and one or more food items F (e.g., smallpotatoes as shown in FIGS. 6 and 7) can be disposed in each of thereceptacles 35. Alternatively, the insert 9 may be sized and shaped tohold food items of a different or same quantity in more than one layerand/or in different row/column arrangements, or just a single food item.For example, the insert 9 could have alternative receptacle 35arrangements with different numbers of longitudinal ribs 33 and/orlateral ribs 31 (e.g., 1×6, 2×6, 4×3, 3×8, 2×2, 3×4, 2×9, 3×6, etc.). Inone embodiment, the lateral ribs 31 and/or the longitudinal ribs 33could be longer to accommodate additional longitudinal ribs 33 and/orlateral ribs 31 and/or the spacing between the lateral ribs 31 and/orthe longitudinal ribs 33 could be reduced to accommodate additionallongitudinal ribs 33 and/or lateral ribs 31. In one embodiment, thespacing between the ribs 31, 33 could be selected for formingreceptacles 35 that are appropriately sized to receive a particular fooditem F.

As shown in FIGS. 3A and 3B, each of the ribs 31, 33 can have agenerally horizontal top edge and bottom edge and generally oblique sideedges corresponding to the oblique sidewall 23 of the tray 7. In theillustrated embodiment, each of the ribs 31, 33 can include two opposingfaces 40, and each face 40 of each of the ribs 31, 33 can include amicrowave energy interactive material (e.g., susceptor) 41 so that atleast the sides 36 a, 36 b of each of the receptacles 35 defined by theribs 31, 33 has a susceptor when the insert 9 is assembled (FIGS. 2A,2B, 5A, and 5B). In one embodiment, the sides 36 c defined by thesidewall 23 of the tray 7 can include a susceptor.

As shown in FIG. 3A, each of the lateral ribs 31 has three notches 43 incommunication with the bottom edge of the respective rib. Similarly, asshown in FIG. 4B, each of the longitudinal ribs 33 has seven notches 45in communication with the top edge of the respective rib. Each of thenotches 43, 45 can be wider at the respective edge of the respective rib31, 33 and can taper to a slit in the interior of the respective rib(e.g., each notch 43 has a tapered portion 44 a extending from thebottom edge of the respective lateral rib 31 and a slit portion 44 bextending from the respective tapered portion 44 a, and each notch 45has a tapered portion 46 a extending from the bottom edge of therespective longitudinal rib 33 and a slit portion 46 b extending fromthe respective tapered portion 46 a). In the illustrated embodiment, thesize of the receptacles 35 in the lateral direction L2 and thelongitudinal direction L1 can be controlled by the spacing between therespective notches 43, 45. In one embodiment, the ribs 31, 33 can be cutinto individual pieces from a roll stack laminated with susceptor and/orwith a predefined focus susceptor on either or both sides of the rollstack. In one exemplary embodiment, each rib 31, 33 can comprise 24gapaperboard laminate with 48ga susceptor film on each side. Any of theribs 31, 33 could be omitted or could be otherwise shaped, arranged,positioned, and/or configured without departing from the disclosure. Forexample one or more of the ribs could have ends with any suitable shapes(e.g., to accommodate a sidewall and/or a bottom wall of a tray withdifferent shapes).

As shown in FIG. 4, the insert 9 can be assembled by aligning each ofthe notches 43 in a lateral rib 31 with respective notches 45 inrespective longitudinal ribs 33 and moving the ribs 31, 33 together sothat notches 43, 45 respectively engage one another (e.g., so that aslit portion 44 b of a notch 43 engages a slit portion 46 b of arespective notch 45). Accordingly, the ribs 31, 33 are interlocked atthe notches 43, 45 and generally support one another. Subsequently, theremaining lateral ribs 31 are assembled onto the longitudinal ribs 33 inthe same or a similar manner. In the illustrated embodiment, the ribs31, 33 are generally the same height so that the top edges of the ribsare all generally in a plane and the bottom edges of the ribs 31, 33 areall generally in another plane. Alternatively, one or more of the ribs31, 33 could be taller or shorter than the other ribs 31, 33. Forexample, some or all of the lateral ribs 31 could be shorter than thelongitudinal ribs 33. The ribs 31, 33 could be assembled by otherassembly steps and/or in a different order without departing from thedisclosure.

As shown in FIGS. 2A and 2B, the central panel 37 can be added to theassembled ribs 31, 33 such as by gluing the center panel 37 to thelateral ribs 31 and/or the longitudinal ribs 33. In one embodiment, oneor more of the ribs 31, 33 can be recessed to accommodate the centralpanel 37 and/or the recess 39 in the central panel 37. The insert 9could be otherwise assembled without departing from the disclosure. Forexample, the central panel 37 could be omitted.

As shown in FIGS. 5A and 5B, the insert 9 (e.g., with the central panel37 omitted) can be transitioned between a collapsed configuration (FIG.5A) to the erected configuration (FIGS. 2A and 2B) with an intermediateconfiguration (FIG. 5B) therebetween. In one embodiment, the erectedconfiguration of the insert 9 can have generally rectangular receptacles35 with lateral ribs 31 that are generally perpendicular to thelongitudinal ribs 33. The insert 9 can be arranged in the collapsed orflattened configuration shown in FIG. 5A for storage and/ortransportation of the insert for example. In one embodiment, the insert9 can be transitioned to the collapsed configuration from the erectedconfiguration by pushing on opposing corners of the erected insert 9. Inone exemplary embodiment, the pushing on the opposing corners of theinsert 9 can cause the ribs 31, 33 to pivot with respect to one anotherat the respective interconnections of the notches 43, 45 (e.g., at therespective intersections of the ribs) so that the ribs 31, 33 are nolonger generally perpendicular to one another (e.g., as shown in FIG.5B). Continued pushing on the opposing corners of the insert 9 can causethe ribs 31, 33 to come into face-to-face contact with adjacent ribs 31,33 so that the insert 9 is generally flattened (FIG. 5A). The insert 9can be transitioned from the collapsed configuration of FIG. 5A to theerected configuration of FIGS. 2A and 2B by pulling on the opposingcorners of the insert that are disposed along the sides of the flattenedinsert, or by pushing on the ends of the flattened insert, which endsare opposing corners of the erected insert. The insert 9 could beotherwise transitioned between a flattened or collapsed configurationand an erected configuration and/or between any suitable configurationswithout departing from the disclosure.

As shown in FIG. 6, a package 51 can include the tray 7 and the insert 9of the container 5 and a food item F (e.g., potatoes) disposed in eachof the receptacles 35 of the insert 9 in the interior 11 of the tray 7.Since the tray has a susceptor 27 on the bottom wall 21, and the ribs31, 33 have susceptors 41 on their faces 40, each food item F can be incontact with and/or in close proximity to a susceptor 27, 41 on multiplesides. Accordingly, the insert 9 can help increase and/or optimize theamount of surface area of the food items F that is in contact with asusceptor, which can help with browning and/or crisping additionalsurface of the food items F. Additionally, as shown in FIG. 6, the fooditems F are compartmentalized by the insert so that the food items F arenot on top of one another or in contact with one another. In oneembodiment, the compartmentalization of the food items F can help retainthe food items F in areas of the container 5 where the heat and/ormicrowave energy is generally evenly distributed (e.g., the food items Fare retained outside the area covered by the center panel 37 where themicrowave energy can be lower due to the electromagnetic fielddistribution in the container 5 when exposed to microwave energy).

The package 51 can also include a cover or film (not shown), such as aheat sealable polyethylene film, attached to the flange 25, for example.In an alternative embodiment shown in for example in FIG. 7, a sleeve orcover 53 with a susceptor layer (not shown) can cover or at leastpartially cover the container 5 to form a package 51′. In oneembodiment, a cover with a susceptor can shield the interior of thecontainer 5 from some or all of the microwave energy to which thepackage is exposed.

In the illustrated embodiment, when the package 51 is exposed tomicrowave energy (e.g., in a microwave oven), the food items F can begenerally evenly heated directly by the microwave energy in the interior11 of the container 5 since the food items F are evenly distributed inan area of the container 5 that has generally even electromagnetic fielddistribution (e.g., as compared to the interior portion covered by thecenter panel 37). Additionally, since multiple sides of the food items Fare in contact with and/or close proximity to the susceptors 27, 41, thefood items F can be heated, browned, and/or crisped by the susceptors27, 41. In one embodiment, the additional paperboard provided by theinsert 9 also can help absorb moisture (e.g., from condensation) thatwould otherwise collect on the bottom wall of the tray 7 and cause atleast a portion of the food items F to become soggy. Accordingly,heating the package 51 in a microwave oven can result in generallyevenly heated food items F with a desirably soft and moist interior andcrispy and/or drier exterior (e.g., for potatoes). In comparison, in oneexperimental example, food items F (potatoes) were heated in the tray 7without the insert 9. The result was a much larger temperature gradientbetween different potatoes. Longer heating times without the insert 9only increased the temperature gradient between individual potatoes anddid not improve the heating of the potatoes. In contrast, as notedabove, heating the potatoes with the insert 9 in the tray 7 resulted ina low temperature gradient between the different potatoes.

FIGS. 8A and 8B are views of a container 105 according to a secondembodiment of the disclosure. The second embodiment is generally similarto the first embodiment, except for variations noted and variations thatwill be apparent to one of ordinary skill in the art. Accordingly,similar or identical features of the embodiments have been given like orsimilar reference numbers. As shown in FIG. 8A, the container 105includes a generally rectangular tray 107 with square corners.Alternatively, the tray 107 could have rounded corners or could be anysuitable shape. The container 105 also includes an insert 109 withtriangular receptacles 135. The receptacles 135 can be formed by obliquesidewalls 131, a longitudinal sidewall 133, and the sidewalls 123 of thetray 107. In an alternative embodiment, the insert 109 could includemore than one longitudinal sidewall 133. The sidewalls 131, 133 could besimilar to the ribs 31, 33 in the first embodiment. Alternatively, thesidewalls could be formed by any suitable features. Any or all of thesurfaces of the sidewalls 131, 133 can include a susceptor film or othermicrowave energy interactive element thereon. Additionally, the bottomwall 121 and/or the sidewall 123 of the tray 107 can include a susceptorfilm or other microwave energy interactive element. The container 105,including the tray 107 and/or the insert 109, could be otherwise shaped,arranged, positioned, and/or configured without departing from thedisclosure. For example, the receptacles 135 could have any suitableshape (e.g., in one embodiment, the receptacles could be hexagons suchas for food items with circular or cylindrical geometries).

Any of the features of the various embodiments of the disclosure can becombined with, replaced by, or otherwise configured with other featuresof other embodiments of the disclosure without departing from the scopeof this disclosure.

Optionally, one or more portions of the blank or other constructsdescribed herein or contemplated hereby may be coated with varnish,clay, or other materials, either alone or in combination. The coatingmay then be printed over with product advertising or other informationor images. The blanks or other constructs also may be selectively coatedand/or printed so that less than the entire surface area of the blank orsubstantially the entire surface area of the blank may be coated and/orprinted.

As noted above with reference to the susceptors 27, 41, any of theblanks, containers, inserts, or other constructs of this disclosure mayoptionally include one or more features that alter the effect ofmicrowave energy during the heating or cooking of a food item that isassociated with the tray or other construct. For example, the blank,tray, container, or other construct may be formed at least partiallyfrom one or more microwave energy interactive elements (hereinaftersometimes referred to as “microwave interactive elements”) that promoteheating, browning and/or crisping of a particular area of the food item,shield a particular area of the food item from microwave energy toprevent overcooking thereof, or transmit microwave energy towards oraway from a particular area of the food item. Each microwave interactiveelement comprises one or more microwave energy interactive materials orsegments arranged in a particular configuration to absorb microwaveenergy, transmit microwave energy, reflect microwave energy, or directmicrowave energy, as needed or desired for a particular construct andfood item.

In the case of a susceptor or shield, the microwave energy interactivematerial may comprise an electroconductive or semiconductive material,for example, a vacuum deposited metal or metal alloy, or a metallic ink,an organic ink, an inorganic ink, a metallic paste, an organic paste, aninorganic paste, or any combination thereof. Examples of metals andmetal alloys that may be suitable include, but are not limited to,aluminum, chromium, copper, inconel alloys (nickel-chromium-molybdenumalloy with niobium), iron, magnesium, nickel, stainless steel, tin,titanium, tungsten, and any combination or alloy thereof.

Alternatively, the microwave energy interactive material may comprise ametal oxide, for example, oxides of aluminum, iron, and tin, optionallyused in conjunction with an electrically conductive material. Anothermetal oxide that may be suitable is indium tin oxide (ITO). ITO has amore uniform crystal structure and, therefore, is clear at most coatingthicknesses.

Alternatively still, the microwave energy interactive material maycomprise a suitable electroconductive, semiconductive, or non-conductiveartificial dielectric or ferroelectric. Artificial dielectrics compriseconductive, subdivided material in a polymeric or other suitable matrixor binder, and may include flakes of an electroconductive metal, forexample, aluminum.

In other embodiments, the microwave energy interactive material may becarbon-based, for example, as disclosed in U.S. Pat. Nos. 4,943,456,5,002,826, 5,118,747, and 5,410,135.

In still other embodiments, the microwave energy interactive materialmay interact with the magnetic portion of the electromagnetic energy inthe microwave oven. Correctly chosen materials of this type canself-limit based on the loss of interaction when the Curie temperatureof the material is reached. An example of such an interactive coating isdescribed in U.S. Pat. No. 4,283,427.

The use of other microwave energy interactive elements is alsocontemplated. In one example, the microwave energy interactive elementmay comprise a foil or high optical density evaporated material having athickness sufficient to reflect a substantial portion of impingingmicrowave energy. Such elements typically are formed from a conductive,reflective metal or metal alloy, for example, aluminum, copper, orstainless steel, in the form of a solid “patch” generally having athickness of from about 0.000285 inches to about 0.005 inches, forexample, from about 0.0003 inches to about 0.003 inches. Other suchelements may have a thickness of from about 0.00035 inches to about0.002 inches, for example, 0.0016 inches.

In some cases, microwave energy reflecting (or reflective) elements maybe used as shielding elements where the food item is prone to scorchingor drying out during heating. In other cases, smaller microwave energyreflecting elements may be used to diffuse or lessen the intensity ofmicrowave energy. One example of a material utilizing such microwaveenergy reflecting elements is commercially available from GraphicPackaging International, Inc. (Marietta, Ga.) under the trade nameMicroRite® packaging material. In other examples, a plurality ofmicrowave energy reflecting elements may be arranged to form a microwaveenergy distributing element to direct microwave energy to specific areasof the food item. If desired, the loops may be of a length that causesmicrowave energy to resonate, thereby enhancing the distribution effect.Microwave energy distributing elements are described in U.S. Pat. Nos.6,204,492, 6,433,322, 6,552,315, and 6,677,563, each of which isincorporated by reference in its entirety.

If desired, any of the numerous microwave energy interactive elementsdescribed herein or contemplated hereby may be substantially continuous,that is, without substantial breaks or interruptions, or may bediscontinuous, for example, by including one or more breaks or aperturesthat transmit microwave energy. The breaks or apertures may extendthrough the entire structure, or only through one or more layers. Thenumber, shape, size, and positioning of such breaks or apertures mayvary for a particular application depending on the type of constructbeing formed, the food item to be heated therein or thereon, the desireddegree of heating, browning, and/or crisping, whether direct exposure tomicrowave energy is needed or desired to attain uniform heating of thefood item, the need for regulating the change in temperature of the fooditem through direct heating, and whether and to what extent there is aneed for venting.

By way of illustration, a microwave energy interactive element mayinclude one or more transparent areas to effect dielectric heating ofthe food item. However, where the microwave energy interactive elementcomprises a susceptor, such apertures decrease the total microwaveenergy interactive area, and therefore, decrease the amount of microwaveenergy interactive material available for heating, browning, and/orcrisping the surface of the food item. Thus, the relative amounts ofmicrowave energy interactive areas and microwave energy transparentareas may be balanced to attain the desired overall heatingcharacteristics for the particular food item.

As another example, one or more portions of a susceptor may be designedto be microwave energy inactive to ensure that the microwave energy isfocused efficiently on the areas to be heated, browned, and/or crisped,rather than being lost to portions of the food item not intended to bebrowned and/or crisped or to the heating environment. Additionally oralternatively, it may be beneficial to create one or morediscontinuities or inactive regions to prevent overheating or charringof the food item and/or the construct including the susceptor.

As still another example, a susceptor may incorporate one or more “fuse”elements that limit the propagation of cracks in the susceptor, andthereby control overheating, in areas of the susceptor where heattransfer to the food is low and the susceptor might tend to become toohot. The size and shape of the fuses may be varied as needed. Examplesof susceptors including such fuses are provided, for example, in U.S.Pat. No. 5,412,187, U.S. Pat. No. 5,530,231, U.S. Patent ApplicationPublication No. US 2008/0035634A1, published Feb. 14, 2008, and PCTApplication Publication No. WO 2007/127371, published Nov. 8, 2007, eachof which is incorporated by reference herein in its entirety.

The blanks according to the present invention can be, for example,formed from coated paperboard and similar materials. For example, theinterior and/or exterior sides of the blanks can be coated with a claycoating. The clay coating may then be printed over with product,advertising, price coding, and other information or images. The blanksmay then be coated with a varnish to protect any information printed onthe blanks. The blanks may also be coated with, for example, a moisturebarrier layer, on either or both sides of the blanks.

In accordance with the exemplary embodiments, the blanks and/or otherconstructs may be constructed of paperboard of a caliper such that it isheavier and more rigid than ordinary paper. The blanks can also beconstructed of other materials, such as cardboard, hard paper, or anyother material having properties suitable for enabling the cartonpackage to function at least generally as described above.

The foregoing description illustrates and describes various embodimentsof the present disclosure. As various changes could be made in the aboveconstruction without departing from the scope of the disclosure, it isintended that all matter contained in the above description or shown inthe accompanying drawings shall be interpreted as illustrative and notin a limiting sense. Furthermore, the scope of the present disclosurecovers various modifications, combinations, and alterations, etc., ofthe above-described embodiments. Additionally, the disclosure shows anddescribes only selected embodiments, but various other combinations,modifications, and environments are contemplated and are within thescope of the inventive concept as expressed herein, commensurate withthe above teachings, and/or within the skill or knowledge of therelevant art. Furthermore, certain features and characteristics of eachembodiment may be selectively interchanged and applied to otherillustrated and non-illustrated embodiments without departing from thescope of the disclosure.

What is claimed is:
 1. A container for heating a plurality of food itemswith microwave energy, the container comprising: a tray comprising asidewall extending at least partially around an interior of the tray; aninsert disposed at least partially in the interior of the tray, theinsert comprising a plurality of lateral ribs, a plurality oflongitudinal ribs, and a central panel extending over at least onelateral rib of the plurality of lateral ribs and at least onelongitudinal rib of the plurality of longitudinal ribs, wherein thecentral panel contacts the at least one lateral rib and the at least onelongitudinal rib along respective portions of respective top edges ofthe at least one lateral rib and the at least one longitudinal rib, andthe portions of the top edges of the at least one lateral rib and the atleast one longitudinal rib are recessed to at least partiallyaccommodate the central panel; and a plurality of receptacles at leastpartially defined by the insert, each receptacle of the plurality ofreceptacles being for at least partially receiving at least one fooditem of the plurality of food items; wherein each lateral rib of theplurality of lateral ribs engages each longitudinal rib of the pluralityof longitudinal ribs to at least partially form the plurality ofreceptacles.
 2. The container of claim 1, wherein a microwave energyinteractive element extends along each of the receptacles of theplurality of receptacles.
 3. The container of claim 1, wherein each ofthe receptacles of the plurality of receptacles comprises a plurality ofsides defined by the insert, and each side of the plurality of sidesdefined by the insert comprises a microwave energy interactive material.4. The container of claim 3, wherein the tray further comprises a bottomwall comprising a microwave energy interactive material.
 5. Thecontainer of claim 3, wherein a lateral rib of the plurality of lateralribs intersects with a longitudinal rib of the plurality of longitudinalribs to at least partially form multiple receptacles of the plurality ofreceptacles.
 6. The container of claim 5, wherein each of the lateralrib and the longitudinal rib defines a side of the plurality of sidesfor each receptacle of the multiple receptacles.
 7. The container ofclaim 6, wherein each of the lateral rib and the longitudinal ribcomprises two faces each having the microwave energy interactivematerial disposed thereon.
 8. The container of claim 1, wherein each ofthe lateral ribs and the longitudinal ribs defines a side of theplurality of sides for respective receptacles of the plurality ofreceptacles, and each of the lateral ribs and the longitudinal ribscomprises two faces each having the microwave energy interactivematerial disposed thereon.
 9. The container of claim 1, wherein alateral rib of the plurality of lateral ribs intersects with alongitudinal rib of the plurality of longitudinal ribs to at leastpartially form multiple receptacles of the plurality of receptacles. 10.The container of claim 9, wherein each of the lateral rib and thelongitudinal rib defines at least one side of each receptacle of themultiple receptacles.
 11. The container of claim 9, wherein the lateralrib comprises a first notch and the longitudinal rib comprises a secondnotch, the first notch and second notch engaging one another at anintersection of the lateral rib and the longitudinal rib.
 12. Thecontainer of claim 11, wherein the top edge of the lateral rib isgenerally coplanar with the top edge of the longitudinal rib.
 13. Thecontainer of claim 12, wherein one of the first notch and the secondnotch is in communication with the top edge of the respective lateralrib and longitudinal rib, and one of the first notch and the secondnotch is in communication with a bottom edge of the respective lateralrib and longitudinal rib.
 14. The container of claim 11, wherein each ofthe first notch and the second notch comprises a tapered portionextending from an edge of the respective lateral rib and longitudinalrib and a slit portion extending from the respective tapered portion.15. The container of claim 1, wherein each receptacle of the pluralityof receptacles comprises a plurality of sides defined by the insert, andeach side of the plurality of sides defined by the insert for eachreceptacle comprises a respective portion of a respective one of theplurality of lateral ribs and the plurality of longitudinal ribs. 16.The container of claim 1, wherein each lateral rib of the plurality oflateral ribs comprises a plurality of first notches and eachlongitudinal rib of the plurality of longitudinal ribs comprises aplurality of second notches, and each first notch engages a respectivesecond notch.
 17. The container of claim 1, wherein the central panel isat least partially attached to the top edge of each of the at least onelateral rib and the at least one longitudinal rib.
 18. The container ofclaim 1, wherein the central panel comprises a recess for holding asecondary food item, and the top edges of the at least one lateral riband the at least one longitudinal rib are further recessed to at leastpartially accommodate the recess in the central panel.
 19. The containerof claim 1, wherein the central panel comprises a recess for receiving asecondary container holding a secondary food item.
 20. The container ofclaim 1, wherein the plurality of receptacles is a first plurality ofreceptacles, and the central panel extends over a second plurality ofreceptacles at least partially defined by the insert.
 21. The containerof claim 20, wherein the second plurality of receptacles comprises fourreceptacles at least partially covered by the central panel, and thecentral panel engages three lateral ribs of the plurality of lateralribs and three longitudinal ribs of the plurality of longitudinal ribs.22. An insert for being disposed in an interior of a tray to form acontainer for heating a plurality of food items with microwave energy,the insert comprising: a plurality of lateral ribs; a plurality oflongitudinal ribs, each lateral rib of the plurality of lateral ribsengaging each longitudinal rib of the plurality of longitudinal ribs; aplurality of receptacles at least partially defined by at least one ofthe lateral ribs of the plurality of lateral ribs and at least one ofthe longitudinal ribs of the plurality of longitudinal ribs, eachreceptacle of the plurality of receptacles being for receiving at leastone food item of the plurality of food items; and a central panelextending over at least one lateral rib of the plurality of lateral ribsand at least one longitudinal rib of the plurality of longitudinal ribs,wherein the central panel contacts the at least one lateral rib and theat least one longitudinal rib along respective portions of respectivetop edges of the at least one lateral rib and the at least onelongitudinal rib, and the portions of the top edges of the at least onelateral rib and the at least one longitudinal rib are recessed to atleast partially accommodate the central panel.
 23. The insert of claim22, wherein a microwave energy interactive element extends along each ofthe receptacles of the plurality of receptacles.
 24. The insert of claim22, wherein each of the receptacles of the plurality of receptaclescomprises a plurality of sides defined by the insert, and each side ofthe plurality of sides defined by the insert comprises a microwaveenergy interactive material.
 25. The insert of claim 24, wherein each ofthe lateral ribs and the longitudinal ribs defines a side of theplurality of sides for respective receptacles of the plurality ofreceptacles.
 26. The insert of claim 25, wherein each of the lateralribs and the longitudinal ribs comprises two faces each having themicrowave energy interactive material disposed thereon.
 27. The insertof claim 22, wherein each receptacle of the plurality of receptaclescomprises a plurality of sides defined by the insert, and each side ofthe plurality of sides defined by the insert for each receptaclecomprises a respective portion of a respective one of the plurality oflateral ribs and the plurality of longitudinal ribs.
 28. The insert ofclaim 22, wherein each lateral rib of the plurality of lateral ribscomprises a plurality of first notches and each longitudinal rib of theplurality of longitudinal ribs comprises a plurality of second notches,and each first notch engages a respective second notch.
 29. The insertof claim 28, wherein for each of the lateral ribs of the plurality oflateral ribs, each first notch of the plurality of first notches is incommunication with a first edge of the respective lateral rib, and foreach of the longitudinal ribs of the plurality of longitudinal ribs eachsecond notch of the plurality of second notches is in communication witha second edge of the respective longitudinal rib.
 30. The insert ofclaim 29, wherein the first edge of each of the lateral ribs is a bottomedge of the respective lateral rib, and the second edge of each of thelongitudinal ribs is the top edge of the respective longitudinal rib.31. The insert of claim 28, wherein each of the first notches and thesecond notches comprises a tapered portion extending from an edge of therespective lateral ribs and longitudinal ribs and a slit portionextending from the respective tapered portion.
 32. The insert of claim22, wherein the central panel is at least partially attached to the topedge of each of the at least one lateral rib and the at least onelongitudinal rib.
 33. The insert of claim 22, wherein the central panelcomprises a recess for holding a secondary food item.
 34. The insert ofclaim 22, wherein the central panel comprises a recess for receiving asecondary container holding a secondary food item.
 35. The insert ofclaim 22, wherein the plurality of receptacles is a first plurality ofreceptacles, and the central panel extends over a second plurality ofreceptacles at least partially defined by the insert.
 36. The insert ofclaim 35, wherein the second plurality of receptacles comprises fourreceptacles at least partially covered by the central panel, and thecentral panel engages three lateral ribs of the plurality of lateralribs and three longitudinal ribs of the plurality of longitudinal ribs.37. A method of forming a package, comprising: obtaining a traycomprising a sidewall extending at least partially around an interior ofthe tray; forming the insert by engaging each lateral rib of a pluralityof lateral ribs with each longitudinal rib of a plurality oflongitudinal ribs to at least partially form a plurality of receptacles,wherein the forming the insert further comprises positioning a centralpanel to extend over at least one lateral rib of the plurality oflateral ribs and at least one longitudinal rib of the plurality oflongitudinal ribs, the central panel contacting the at least one lateralrib and the at least one longitudinal rib along respective portions ofrespective top edges of the at least one lateral rib and the at leastone longitudinal rib, and the portions of the top edges of the at leastone lateral rib and the at least one longitudinal rib being recessed toat least partially accommodate the central panel; at least partiallyforming a container by positioning the insert at least partially in theinterior of the tray; and inserting a plurality of food items into thecontainer by positioning at least one food item of the plurality of fooditems at least partially into each receptacle of the plurality ofreceptacles.
 38. The method of claim 37, wherein a microwave energyinteractive element extends along each of the receptacles of theplurality of receptacles.
 39. The method of claim 37, wherein each ofthe lateral ribs of the plurality of lateral ribs comprises a firstnotch and each of the longitudinal ribs of the plurality of longitudinalribs comprises a second notch, and the engaging each lateral rib of theplurality of lateral ribs with each longitudinal rib of the plurality oflongitudinal ribs comprises engaging the first notch and second notchwith one another for each of the lateral ribs and for each of thelongitudinal ribs.
 40. The method of claim 37, wherein the forming theinsert further comprises attaching the central panel to the top edge ofeach of the at least one lateral rib and the at least one longitudinalrib.
 41. The method of claim 37, wherein the central panel comprises arecess, and the method further comprises disposing a secondary food itemin the recess.